Module 1
Module 1
Module 1
Syllabus: Introduction: Closed loop and Open loop Smart Structures. Applications of Smart structures, piezoelectric properties.
Inchworm Linear motor, Shape memory alloys, Shape memory effect-Application, Processing and characteristics.
Shape Memory Alloys: Introduction, Phenomenology, Influence of stress on characteristic temperatures, modelling of shape
memory effect. Vibration control through shape memory alloys. Design considerations, multiplexing embedded NiTiNOL actuators.
Introduction
Since the earliest days of the evolution of mankind, the main distinguishing features between human beings and other
mammals has been the ability to use and develop materials to satisfy our human requirements. Materials science and
engineering plays a vital role in this modern age of science and technology. Various kinds of materials are used in
industry, housing, agriculture, transportation, etc. to meet the plant and individual requirements. Most materials doesn't
exist in its pure shape, it is always exist as a ores.
For centuries, metals have played an important role as structural materials. Techniques of alloying, smelting, and forging
have been evolving since the bronze and iron ages. With advancements in science and technology, and a deeper
understanding of the effects of microstructure and processing techniques on the material behaviour, the field of material
science has radically improved through the past decades. The capability to engineer different material properties
(mechanical, thermal, electrical, etc.) for a variety of applications has enabled the development of new alloys and
composites.
Science and technology have made amazing developments in the design of electronics and machinery using standard
materials, which do not have particularly special properties (i.e. steel, aluminium, gold). Imagine the range of
possibilities, which exist for special materials that have properties, scientists can manipulate. Some such materials have
the ability to change shape or size simply by adding a little bit of heat, or to change from a liquid to a solid almost
instantly when near a magnet; these materials are called smart materials
To be able to select a material for a given use based on considerations of cost and performance.
To understand the limits of materials and the change of their properties with use.
To be able to create a new material that will have some desirable properties.
Classification of materials
1. Metals and alloys
2. Polymers (Plastics)
3. Semiconductors
4. Composite materials
5. Ceramics, glasses and glass –ceramics
Metals and alloys – These include steels, Al, CI, Mg, Zn, Ti, Cu, Ni. In general, metals have good electrical and thermal
conductivity. Metals and alloys have relatively high strength, high, stiffness, ductility or formability and shock resistance. They are
particularly useful for structural or load bearing applications. Metals and alloys provide combinations of properties.
Polymers - Polymers are typically organic materials. They are produced using a process known as polymerization. Polymeric
materials include rubber (elastomers) and many types of adhesives. Polymers typically are good electrical and thermal insulators
although there are exceptions such as the semiconducting polymers. Although they have lower strength, polymers have a very good
strength-to-weight ratio. They are typically not suitable for use at high temperatures. Many polymers have very good resistance to
corrosive chemicals. Polymers have thousands of applications ranging from bulletproof vests, compact disks (CDs), ropes, and
liquid crystal displays (LCDs) to clothes and coffee cups.
Semiconductors - Silicon, germanium, and gallium arsenide-based semiconductors such as those used in computers and electronics
are part of a broader class of materials known as electronic materials. The electrical conductivity of semiconducting materials is
between that of ceramic insulators and metallic conductors. Semiconductors have enabled the information age. In some
semiconductors, the level of conductivity can be controlled to enable electronic devices such as transistors, diodes, etc., that are used
Dr. Chetan Byrappa, Assistant Professor, Dept. of Mechanical Engineering, B.I.T
to build integrated circuits. In many applications, we need large single crystals of semiconductors. These are grown from molten
materials. Often, thin films of semiconducting materials are also made using specialized processes.
Composites
A "composite" is when two or more different materials are combined together to create a superior and unique material. Composites
are multifunctional materials having unprecedented mechanical and physical properties that can be tailored to meet the requirements
of a particular application.
The ‘composites’ concept is not a human invention. Wood is a natural composite material consisting of one species of polymer —
cellulose fibres with good strength and stiffness — in a resinous matrix of another polymer, the polysaccharide lignin. Nature makes
a much better job of design and manufacture than we do, although Man was able to recognize that the way of overcoming two major
disadvantages of natural wood — that of size (a tree has a limited transverse dimension), and that of anisotropy (properties are
markedly different in the axial and radial directions) — was to make the composite material that we call plywood. Bone, teeth and
mollusc shells are other natural composites, combining hard ceramic reinforcing phases in natural organic polymer matrices. Man
was aware, even from the earliest times, of the concept that combining materials could be advantageous, and the down-to-earth
procedures of wattle-and-daub (mud and straw) and ‘pide’ (heather incorporated in hard-rammed earth) building construction, still
in use today, pre-date the use of reinforced concrete by the Romans which foreshadowed the pre-tensioned and post-tensioned
reinforced concretes of our own era. But it is only in the last half century that the science and technology of composite materials
have developed to provide the engineer with a novel class of materials and the necessary tools to enable him to use them
advantageously.
Controller
Fig 1.1: General block diagram of open loop system
An open-loop controller is often used in simple processes because of its simplicity and low cost, especially in systems where
feedback is not critical. An open-loop controller, also called a non-feedback controller, is a type of controller that computes its input
into a system using only the current state and its model of the system. A characteristic of the open-loop controller is that it does not
use feedback to determine if its output has achieved the desired goal of the input. This means that the system does not observe the
output of the processes that it is controlling. It also may not compensate for disturbances in the system.
Typical examples: Washing Machine, for which the length of machine wash time is entirely dependent on the judgment and
estimation of the human operator. Some Irrigation Sprinklers are programmed to turn on/off at set times. It does not measure soil
moisture as a form of feedback. Even if rain is pouring down on the lawn, the sprinkler system would activate on schedule, wasting
water.
A closed-loop controller uses feedback to control states or outputs of a dynamical system. Its name comes from the information path
in the system: Process inputs have an effect on the process outputs, which is measured with sensors and processed by the controller;
the result (the control signal) is used as input to the process, closing the loop.
Smart Structures
A smart structure is a system containing multifunctional parts that can perform sensing, control, and actuation. Smart structure
involves distributed actuators and sensors, and one or more microprocessors that analyze the responses from the sensors and use
integrated control theory to command the actuators to apply localized strains or displacements to alter system response. A smart
structure has the capability to respond to a changing external environment (such as load or shape change) as well as to a changing
internal environment (such as damage or failure). It incorporates smart material actuators that allow the alteration of system
characteristics (such as stiffness or damping) as well as of system response (such as strain or shape) in a controlled manner. Thus, a
smart structure involves five key elements: actuators, sensors, control strategies, power and signal conditioning electronics, and a
computer. Many types of actuators and sensors, such as piezoelectric materials, shape memory alloys, electrostrictive materials,
magnetostrictive materials, electro- and magneto-rheological fluids, and fiber optics, are being considered for various applications.
These can be integrated with main load carrying structures by surface bonding or embedding without causing any significant
changes in the mass or structural stiffness of the system.
A smart or intelligent structure incorporates distributed actuators and sensors as well as control logic, processors, and power
electronics. Fig. 1.3 defines various types of structures.
Adaptive Structures (A): have distributed actuators to alter characteristics in a prescribed manner. They may not have sensors.
Examples are conventional aircraft wings with flaps and ailerons, and rotor blades with servo-flaps.
Sensory Structures (B): have distributed sensors to monitor the characteristics of the structure (health monitoring). Sensors may
detect strain, displacement, acceleration, temperature, electromagnetic properties, and extent of damage.
Controlled Structures (C): overlap both adaptive and sensory structures. These constitute actuators, sensors, and a feedback
control system to actively control the characteristics of the structure.
Active Structures (D): are a subset of controlled structures. Integrated actuators and sensors have load carrying capability
(structural functionality).
Intelligent or Smart Structures (E): are a subset of active structures. Additionally, they have highly integrated control logic and
power electronics.
Numerous applications of smart structures technology to various physical systems are evolving to actively control vibration, noise,
aero elastic stability, damping, shape change, and stress distribution. Applications range from space systems to fixed-wing and
rotary-wing aircraft, automotive, civil structures, machine tools, and medical systems. At this time, servo valve hydraulic actuators
are widely used in aerospace and other applications because of their reliable performance over a large range of force, stroke, and
bandwidth. Their drawbacks, such as mechanical complexity, need for hydraulic tubing and reservoir, and size and weight, present
an opportunity to search for light weight compact actuators such as smart material actuators.
A smart material is defined as a material that transforms its characteristics, such as mechanical states (strain, position or velocity) or
material characteristics, (stiffness, damping, or viscosity) under external field (electric, magnetic, or thermal). Much of the early
development of smart structures methodology was driven by space applications such as vibration and shape control of large flexible
space structures, but now wider applications are envisaged for aeronautical and other systems.
Dr. Chetan Byrappa, Assistant Professor, Dept. of Mechanical Engineering, B.I.T
Embedded or surface-bonded smart actuators on an airplane wing or a helicopter blade, for example, can induce airfoil twist/camber
change that in turn can cause a variation of lift distribution and may help control static and dynamic aero elastic problems.
Applications of smart structures technology to aerospace and other systems are expanding rapidly. Major barriers include low
actuator stroke, the lack of a reliable smart material characteristics database, non-availability of robust distributed adaptive control
strategies, and inadequate mathematical modelling and analysis of smart systems.
Smart Materials
Smart materials are materials that have one or more properties that can be significantly altered in a controlled fashion by external
stimuli, such as stress, temperature, moisture, pH, electric or magnetic fields.
Structural materials – Are generally used in load bearing situations & are characterized by their mechanical strength.
Smart materials – Used to design the smart structures, which possess not only the inherent mechanical strength, but also they will
have the functional characteristics.
Piezoelectric materials are materials that produce a voltage when stress is applied. Since this effect also applies in the reverse
manner, a voltage across the sample will produce stress within the sample. Suitably designed structures made from these materials
can therefore be made that bend, expand or contract when a voltage is applied.
Piezoelectric materials have been used in thousands of applications in a wide variety of products in the consumer, industrial,
medical, aerospace, and military sectors. When a piezoelectric material is subjected to a mechanical stress, an electric charge is
generated across the material. The ability of a material to generate a charge or electric field when subjected to a stress is measured
by the piezoelectric voltage coefficient g.
The piezoelectric effect of natural monocrystalline materials such as quartz, tourmaline and Rochelle salt is relatively small.
Polycrystalline ferroelectric ceramics such as barium titanate (BaTiO3) and lead zirconate titanate(PZT) exhibit larger
displacements or induce larger electric voltages.
Industry Application
Automotive Air bag sensor, air flow sensor, audible alarms, fuel atomiser, keyless door entry, seat belt buzzers, knock
sensors.
Consumer Cigarette lighters, depth finders, fish finders, humidifiers, jewellery cleaners, musical instruments, speakers,
telephones.
Shape memory alloys (SMAs) are metals that "remember" their original shapes. Shape Memory Alloys (SMA's) are novel materials
which have the ability to return to a predetermined shape when heated. When an SMA is cold, or below its transformation
temperature, it has a very low yield strength and can be deformed quite easily into any new shape which it will retain. However,
when the material is heated above its transformation temperature it undergoes a change in crystal structure which causes it to return
to its original shape. SMA’s are useful for such things as actuators which are materials that "change shape, stiffness, position,
natural frequency, and other mechanical characteristics in response to temperature or electromagnetic fields. An example is NiTinol
(Nickel Titanium)
The discovery of the shape memory effect was made in 1932 by Swedish researcher Arne Olander in a Gold-Cadmium alloy.
Greninger and Moordian observed the formation of and disappearance of the martensite phase in a copper zinc alloy through the
variation of temperature in 1938. The next discovery of SMA appears to have been reported in 1951 by Chang and Read, who found
the shape memory effect in a Gold (Au) and Cadmium (Cd) alloy. Buehler and Wiley at Naval Ordnance Laboratory showed the
shape memory effect in a Nickel (Ni) and Titanium (Ti) alloy in 1962. It is reported that the discovery of Nitinol occurred by
Above its transformation temperature, Nitinol is superelastic, able to withstand a large amount of deformation when a load is
applied and return to its original shape when the load is removed. Below its transformation temperature, it displays the shape
memory effect. When it is deformed it will remain in that shape until heated above its transformation temperature, at which time it
will return to its original shape.
The high temperature causes the atoms to arrange themselves into the most compact and regular pattern possible. The shape change
involves a solid state phase change involving a molecular rearrangement between Martensite and Austenite
SMAs have two stable phases – the high-temperature phase, called austenite & the low-temperature phase, called martensite.
Types of SMA’s:
• When a shape memory alloy is in its cold state (below as), the metal can be bent or stretched and will hold this shape until heated
above the transition temperature.
• When the metal cools again, it will remain in the hot shape until deformed again.
• In this case, cooling from high temperature does not cause macroscopic shape change.
• This is the effect that the material remembers two shapes: one at high temp and the other at low temperature.
• These metals show shape memory effect during both cooling and heating.
• The metal can be trained to leave some reminders of the deformed low temp condition in the high temp phases.
• Above a certain temp, the metal loses the 2 way memory effect. This is called “amnesia”
Manufacture of SMA
SMA are typically made by casting, using vacuum arc melting or induction melting.
These are specialist techniques used to keep impurities in the alloy to a minimum and ensure the metals are well mixed.
The ingot is then hot rolled into longer sections and then drawn to turn it into wire.
They are then shaped while hot and are cooled rapidly by quenching in water or by cooling with air.
The twinned martensite phase resemble the austenite phase from our point of view, but on an atomic level, the structure is different.
There are phase planes where the martensite can reconfigure itself with 24 crystallographically equivalent habit planes. This is
called twinning because of the symmetry across the planes.
Characteristic temperatures:
M =Martensitic Finish
f
Ms=Martensitic Start
As=Austenitic Start
Af=Austenitic Finish
When martensitic nitinol is subject to external stress it goes through different variations of the possible crystal structures
and eventually settles at the one allowing for maximal deformation. This mechanism is called detwinning. There are four
temperatures characterizing the shape memory effect of SMA:
Mf: martensite finish—this is the lowest temperature, below all of the material has the soft martensitic structure
Ms: martensite start—an intermediate temperature, when the martensite phase starts to appear in the prevalently austenitic
phase
As: austenite start—an intermediate temperature, when the austenite phase starts to appear in the prevalently martensitic
phase
Af: austenite finish—this is the highest temperature, above which all of the material has the hard martensitic structure.
Superelastic SMA are designed to work over this temperature, while the thermal-induced memory effect finishes at this
temperature.
Once it has cooled then it is in the austenite phase & can retain the shape it been given.
Since the mechanical behavior of SMA materials is closely related to the microscopic martensitic phase transformation, the
constitutive relations developed for conventional materials such as Hooke's law and plastic flow theory are not directly applicable.
Hence, specific constitutive relations, which take into consideration the phase transformation behavior of SMA, have been
developed. Two approaches are generally used: (a) the phenomenological (macroscopic) approach, based on extensive experimental
work; and (b) the physical (microscopic) approach using fundamental physical concepts. Hybrid approaches that combine both
approaches to obtain a more accurate description and prediction of the SMA material behavior have also been used. Tanaka’s
model, based on the concept of the free energy driving force, considers a one-dimensional metallic material undergoing phase
transformation. The state variables for the material are strain, ε, temperature, T, and Martensitic fraction, ξ. Then, a general state
variable, Λ, is defined as
Fig 1.9: Stress-strain curves of super elastic Nitinol and other metallic wires: (a) overall behaviour (b) zoom-in on the low-strain
range.
Because of its biocompatibility and superior resistance to corrosion, shape memory alloys such as Nitinol have gained wide usage in
the medical field as bone plates, artificial joints, orthodontic devices, coronary angioplasty probes, arthroscopic instrumentation, etc.
In engineering, these materials have been used as force actuators and robot controls. They also offer vibration control potentials
based on two important principles: (a) the three to four times increase in elastic modulus in the transition from Martensitic to
Austenitic phase; (b) the creation of internal stresses; and (c) the dissipation of energy through inelastic hysteretic damping. These
effects can be practically realized either as additional components to be retrofitted on existing structures, or as
hybrid composite materials containing embedded SMA fibers.
The increase in elastic modulus is used in the active properties tuning (APT) vibration control method. As SMA wires are activated
by heating with electric current or other methods, their modulus increase three fold from 27 GPa to 82 GPa. Depending on the
structural architecture and on how much SMA material is used, this may result in a sizable change in the effective structural
stiffness, and a considerable frequency shift away from an unwanted resonance. The activation speed, which depends on the heating
The creation of internal stresses is used in the active strain energy tuning (ASET) method. The activation of stretched SMA fibers
can make them shrink by 4% to 8% and thus create considerable contractile stress in the support structure. If the SMA fibers are
placed inside beams or plates, active frequency control can be readily achieved, since the presence of in plane compressive stresses
can considerably change the beams and plates natural frequencies. One ready application of this effect is the avoidance of critical
speeds during the run up and run down of high-speed shafts.
In many applications the response time of SMA actuators is ultimately limited by heat transfer. Typically, very rapid heating can be
achieved but the time needed for cooling is long compared to the vibratory period of typical mechanical or civil structures. A unique
approach has been found suitable to overcome this inherent limitation. The approach is based on using several NiTiNOL wires as
actuators in parallel and energizing subsets of these during successive cycles of structural motion, effectively trading reduced
control authority for increased frequency response. Thus, with an array of actuators an effective bandwidth can be achieved that is
demonstrated to be greater than the bandwidth possible with a single actuator.
This technique of multiplexing several actuators was established in principle by the senior author of this paper in 1990. Most
recently, upon completion of the effort reported here, the authors learned that Wilson et al. (1990) had employed a similar approach
to obtain a higher frequency bandwidth. The approach has now been extended to demonstrate its validity by applying it to a robust
box beam made of steel. Furthermore, successful performance of the multiplexing scheme has led to the analysis, design; fabrication
and testing of a composite beam in which NiTiNOL fibers were embedded. A series of vibration tests were conducted on the
composite beam along with temperature measurements using an infrared camera. With the multiplexing approach, the first two
modes of the composite beam, at 23.5 Hz and 144 Hz respectively, were excited. This unique approach can now be developed
further to design structural systems of interest to industry and build smart composite structures. This serves the eventual goal of
controlling vibration at frequencies higher than was thought possible with this material.
Fig 1.10: Cross section of composite beam embedded with NiTiNOL wires
The technique of multiplexing several actuators was established in principle as described above. The approach was extended to
demonstrate its validity by applying it to a robust box of steel. Furthermore, successful performance of the multiplexing scheme has
led to the analysis, design, and fabrication and testing of a composite beam in which NiTiNOL fibers were embedded. A series of
experiments were conducted on the composite beam along with temperature measurements using infrared cameras.
Helicopter blades
Performance for helicopter blades depend on vibrations; with memory metals in micro processing control tabs for the
trailing ends of the blades, pilots can fly with increased precision.
Bioengineering
Bones: Broken bones can be mended with shape memory alloys. The alloy plate has a memory transfer temperature that is
close to body temperature, and is attached to both ends of the broken bone. From body heat, the plate wants to contract and
retain its original shape, therefore exerting a compression force on the broken bone at the place of fracture. After the bone
has healed, the plate continues exerting the compressive force, and aids in strengthening during rehabilitation. Memory
metals also apply to hip replacements, considering the high level of super-elasticity. The photo above shows a hip
replacement.
Reinforcement for Arteries and Veins: For clogged blood vessels, an alloy tube is crushed and inserted into the clogged
veins. The memory metal has a memory transfer temperature close to body heat, so the memory metal expands to open the
clogged arteries.
Dental wires: used for braces and dental arch wires, memory alloys maintain their shape since they are at a constant
temperature, and because of the super elasticity of the memory metal, the wires retain their original shape after stress has
been applied and removed.
Eyeglass Frames
In certain commercials, eyeglass companies demonstrate eyeglass frames that can be bent back and forth, and retain their
shape. These frames are made from memory metals as well, and demonstrate super-elasticity.
Anti-scald devices
Arterial clips
Automotive thermostats
Contraceptive devices
Fibre-optic coupling
Filter struts
Fire dampers
Fire sprinklers
Graft stents
Kettle switches
Keyhole instruments